Seat Assembly Having a Cross Member

ABSTRACT

A seat assembly having a seat back and a support post for supporting a headrest. The seat back may have a cross member that may include a support post opening and a flexible arm that may have a barb. The flexible arm may flex between a latched position in which the barb may be disposed in a notch of the support post to inhibit movement of the support post and an unlatched position in which the barb may be spaced apart from the notch to permit removal of the support post from the support post opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/502,615, filed Apr. 18, 2012, which is the National Stage ofInternational Application No. PCT/US11/21065, filed Jan. 13, 2011, whichclaims the benefit of U.S. Provisional Application No. 61/295,806, filedJan. 18, 2010, the disclosures of which are hereby incorporated in theirentirety by reference herein.

BACKGROUND Field

Embodiments of the present invention relate to seats and frameassemblies for seats.

SUMMARY

In at least one embodiment, a seat assembly is provided. The seatassembly may have a seat back and a support post. The seat back may havea frame assembly that may include a unitary plastic cross member thatmay extend between first and second side members. The cross member mayinclude a first support post opening and a first flexible arm. The firstflexible arm may be disposed in the cross member proximate an end of thefirst support post opening. The first flexible arm may have a firstbarb. The support post may have a first notch. The first flexible arm isconfigured to flex between a latched position in which the first barbmay be disposed in the first notch to inhibit movement of the supportpost and an unlatched position in which the first barb may be spacedapart from the notch to permit removal of the support post from thefirst support post opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary seat assembly.

FIG. 2 is a partially exploded perspective view of a portion of a frameassembly having a cross member.

FIG. 3 is a perspective view of an embodiment of a cross member.

FIG. 4 is a top section view of a portion of the frame assembly.

FIG. 5 is a partial section view of the cross member of FIG. 3.

FIGS. 6 and 7 are plan views of a first embodiment of a support postlatch in first and second positions, respectively.

FIGS. 8 and 9 are top and side views of a second embodiment of a supportpost latch in a latched position.

FIG. 10 is a side view of the second embodiment of the support postlatch in an unlatched position.

FIG. 11 is a top view of a third embodiment of a support post latch in alatched position.

FIG. 12 is an exploded perspective view of the third embodiment of thesupport post latch showing latched and unlatched positions.

FIGS. 13 and 14 are side views of a fourth embodiment of a support postlatch in latched and unlatched positions, respectively.

FIG. 15 is a perspective view of a fifth embodiment of a support postlatch in a latched position.

FIGS. 16 and 17 are side views of the fifth embodiment of a support postlatch in latched and unlatched positions, respectively.

DETAILED DESCRIPTION

Detailed embodiments of the present invention are disclosed herein;however, it is to be understood that the disclosed embodiments aremerely exemplary of the invention that may be embodied in various andalternative forms. The figures are not necessarily to scale, somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for the claims and/or as a representative basis forteaching one skilled in the art to variously employ the presentinvention.

Referring to FIGS. 1 and 2, an exemplary seat assembly 10 is shown. Theseat assembly 10 may be configured for use in a vehicle, such as a motorvehicle like a car or truck.

The seat assembly 10 may include a seat bottom 12 and a seat back 14.The seat bottom 12 may be configured to be mounted on a support surface,such as a floor pan of a vehicle. The seat back 14 may be pivotallydisposed on the seat bottom 12 and may include a frame assembly 16. Aheadrest 18 that is configured to support the head of a seat occupantmay be mounted on the frame assembly 16.

The frame assembly 16 may be configured to provide structural supportfor the seat back 14. In at least one embodiment, the frame assembly 16may include a first side member 20, a second side member 22, and a crossmember 24. The first and second side members 20, 22 may be spaced apartfrom each other and may generally extend away from the seat bottom 12along opposing lateral sides of the seat back 14. The first and secondside members 20, 22 may be made of any suitable material, such as ametal or metal alloy. The first and second side members 20, 22 may beconfigured with a channel or pocket 26 that may be configured to receivethe cross member 24.

Referring to FIGS. 2-4, an exemplary cross member 24 is shown in moredetail. The cross member 24 may have a unitary or one-piececonstruction. The cross member 24 may extend from the first side member20 to the second side member 22 and may be disposed proximate the top ofthe frame assembly 16. As such, the cross member 24 may be configured toreceive one or more support posts 28 that may couple the headrest 18 tothe seat back 14. The cross member 24 may be made of a differentmaterial than the first and second side members 20, 22. For instance,the cross member 24 may be made of a polymeric material, which mayreduce weight, facilitate component integration to reduce the number ofindividual parts, and eliminate welding steps as compared to a frameassembly having a metal cross member or a multi-piece construction.

The cross member 24 may include various features that facilitateassembly and/or structural integrity. In at least one embodiment, thecross member 24 may include one or more upper mounting portions 30, oneor more lower mounting portions 32, a first set of arcuate ribs 34, asecond set of arcuate ribs 36, a first support post mounting portion 38,and a second support post mounting portion 40. These features may beintegrally formed with the cross member 24.

The upper and lower mounting portions 30, 32 may facilitate coupling ofthe cross member 24 to a side member 20, 22. In the embodiment shown, apair of upper mounting portions 30 and a pair of lower mounting portions32 are provided. The upper and lower mounting portions 30, 32 may beconfigured as arms that extend from a central body of the cross member24 toward an associated side member 20, 22. The upper mounting portions30 may be disposed proximate a top surface 42 of the cross member 24.The lower mounting portions 32 may be spaced apart from and disposedbelow the upper mounting portions 30. One upper mounting portion 30 andone lower mounting portion 32 may be configured to be mounted to thefirst side member 20 while the other upper mounting portion 30 and lowermounting portion 32 may be mounted to the second side member 22. In atleast one embodiment, one upper and lower mounting portion 30, 32 may bereceived in the pocket 26 of the first side member 20 and the otherupper and lower mounting portion 30, 32 may be received in the pocket 26of the second side member 22.

The upper and lower mounting portions 30, 32 may include a through hole46 and/or a cavity 48. The through hole 46 may extend from a first sideor first surface 50 of the cross member 24 to a second side or secondsurface 52 disposed opposite the first surface 50. The cavity 48 may bedisposed between and may be spaced apart from the first and secondsurfaces 50, 52. In at least one embodiment, the through hole 46 may bedisposed proximate the midpoint of the through hole 46 and proximate thecenter of a mounting portion 30, 32.

Referring to FIG. 4, a fastener 54 may be used to couple each upper andlower mounting portion 30, 32 to a side member 20, 22. In FIG. 4, thefastener is not sectioned for clarity. In the embodiment shown, thefastener 54 is depicted as a bolt and nut, but may be a rivet, screw, orother type of fastener in various embodiments. The fastener 54 mayextend through at least one hole in an associated side member 20, 22 andinto the through hole 46. In the embodiment shown, two fasteners 54 areinserted through opposite sides of the side member 20 and extend to thecavity 48. The cavity 48 may provide access to assemble or rivet afastener 54. Alternatively, a single fastener 54 may be provided thatmay extend completely through the through hole 46 from the first surface50 to the second surface 52 and through associated holes in a sidemember 20, 22.

Referring to FIGS. 2 and 3, first and second sets of arcuate ribs 34, 36are shown. Members of the first and second sets of arcuate ribs 34, 36may extend from the top surface 42 of the cross member 24 at leastpartially toward a bottom surface 56 disposed opposite the top surface42. Moreover, members of the first and second sets of arcuate ribs 34,36 may extend from the first side or first surface 50 to the second sideor second surface 52 of the cross member 24. The members of a particularset of arcuate ribs 34, 36 may be spaced apart from each other andcurved with respect to a reference point. For instance, members of thefirst set of arcuate ribs 34 may be spaced apart from each other and maybe curved with a concave configuration with respect to the first supportpost mounting portion 38. Similarly, members of the second set ofarcuate ribs 36 may be spaced apart from each other and may be curvedwith a concave configuration with respect to a second support postportion 40. The sets of arcuate ribs 34, 36 may help distribute loadforces exerted on the frame assembly 16 by a seat occupant. Forinstance, the ribs may help distribute load forces exerted on the crossmember 24 in a region between the first and second support post mountingportions 38, 40 outward toward the first and second side members 20, 22.Moreover, each rib that is a member of the first set of arcuate ribs 34may intersect at least one member of the second set of arcuate ribs 36to help distribute load forces.

The first and second support post mounting portions 38, 40 may beprovided with the cross member 24 and configured to receive a supportpost 28. In the embodiment shown, the first and second support postmounting portions 38, 40 are spaced apart from each other.Alternatively, a single support post mounting portion may be provided inone or more embodiments.

The first and second support post mounting portions 38, 40 may havesimilar or identical configurations. In the embodiment shown, the firstand second support post mounting portions 38, 40 each include a supportpost opening 60 that may extend partially through the cross member 24from the top surface 42 toward the bottom surface 56. The support postopening 60 may be disposed along an axis 62.

The support post opening 60 may be at least partially defined by one ormore collars. As is best shown in FIGS. 3 and 5, a first collar 64 and asecond collar 66 may be provided that are spaced apart from each otherand may be coaxially disposed with respect to the axis 62. The firstcollar 64 may extend from and/or above the top surface 42 of the crossmember 24. The second collar 66 may be spaced apart from the firstcollar 64 and may be disposed proximate the bottom surface 56 of thecross member 24. The collars 64, 66 may have first and second slots 70,72. The first and second slots 70, 72 may be spaced apart from eachother and may be disposed directly opposite each other in one or moreembodiments.

A band 74 may be disposed in the support post opening 60. In FIG. 5, theband 74 is not sectioned for clarity. The band 74 may engage anassociated collar 64, 66 and may be received by the first and secondslots 70, 72. In at least one embodiment, the band 74 may have aring-like configuration and may generally extend around and engage thesupport post 28 to account for tolerance variations and to inhibitrattling or vibration. In at least one embodiment, the band 74 may bemade of a metal or metal alloy and may include a first end 76 and asecond end 78. The first and second ends 76, 78 may be disposed ineither the first slot 70 or the second slot 72. One or more indentations80 may be provided on the band 74 that may extend toward and engage thesupport post 28. The indentations 80 may be spaced apart from each otherand may be spaced apart from the cross member 24.

Referring to FIGS. 3, 6, and 7, at least one support post mountingportion 38, 40 may include a latch slot 90 that is configured to receivea latch wire 92. The latch slot 90 may include a latch slot opening 94that may be disposed in the first surface 50 or the second surface 52.The latch wire 92 may be inserted through the latch slot opening 94 andmay move between a first position and a second position.

In FIG. 6, the latch wire 92 is shown in the first position. In thefirst position, the latch wire 92 engages the support post 28 to inhibitmovement. The latch wire 92 may include a contact portion 100 that maybe engaged to actuate the latch wire 92 from the first position to thesecond position. In the embodiment shown, the contact portion 100 iscurved and generally centered in the support post opening 60. One ormore engagement portions 102 may extend from the contact portion 100toward the support post 28. The engagement portions 102 may be receivedin a notch 104 in the support post 28 when in the first position. Aretaining portion 106 may extend at an angle from an end of theengagement portion 102 and generally back toward the latch slot opening94. In the embodiment shown, the retaining portion 106 includes a curvedportion that extends from the engagement portion 102. The retainingportion 106 may have a shorter length than the engagement portion 102.An end 108 of the retaining portion 106 may engage a protrusion 110 thatmay extend from a side wall 112 and a base wall 114 that may at leastpartially define the latch slot 90. The end 108 of the retaining portion106 may engage the protrusion 110 to retain the latch wire 92 in thelatch slot 90 when the latch wire 92 is in the first position. Inaddition, the protrusion 110 may be generally aligned with a side of thesupport post opening 60 to help direct and/or increase pressure exertedby the latch wire 92 upon the support post as compared to a protrusionlocated closer to the support post opening 60. The side wall 112 mayextend from the latch slot opening 94 toward an opposite side of thecross member 24, such as second surface 52.

In FIG. 7, the latch wire 92 is shown in the second position. In thesecond position, the latch wire 92 is spaced apart from the support post28. More specifically, the contact portion 100 may be actuated towardthe support post 28 when sufficient force is exerted upon the contactportion 100. The latch wire 92 may then flex such that the engagementportions 102 disengage the support post 28. In the embodiment shown, theengagement portions 102 move away from each other to disengage a notch104. The curved part of the retaining portion 106 may slide along awedge wall 116 that may extend at an angle from the side wall 112 towardthe support post opening 60. In addition, the retaining portion 106 maybe actuated toward and/or against the side wall 112 and the end 108 ofthe retaining portion 106 may move away from the protrusion 110. Thelatch wire 92 may be configured to return to the first position whensufficient force is not exerted to hold the latch wire 92 in the secondposition.

Referring to FIGS. 8-10, a second embodiment of a support post mountingportion 120 is shown. In FIG. 9, the support post 28 is not sectionedfor clarity. In this embodiment, the top surface 42 of the cross member24 may include one or more tool slots 122 disposed proximate the supportpost opening 60. Each tool slot 122 may be aligned with a flexible arm124 having a barb 126. In FIGS. 8-10, two flexible arms 124 are shownthat are integrally formed with the cross member 24; however, a singleflexible arm 124 may be provided in one or more embodiments. The barb126 may be configured to engage an associated notch 104 in the supportpost 28 when in a latched position to inhibit movement or removal of thesupport post 28 from the support post opening 60 as shown in FIG. 9. Theflexible arm 124 may flex to an unlatched position in which the barb 126is spaced apart from the notch 104 to permit removal of the support post28 from the support post opening 60 as shown in FIG. 10. A tool 128,such as a screwdriver, may be inserted through the tool slot 122 to flexthe flexible arm 124 from the latched position to the unlatchedposition. In addition, a contact surface 130 may be disposed between theflexible arms 124 that may act as an end stop that engages an end of thesupport post 28 to position the support post 28. The contact surface 130may have an arcuate configuration in one or more embodiments.

Referring to FIGS. 11 and 12, a third embodiment of a support postmounting portion 140 is shown. In this embodiment, a single tool slot142 is provided in the top surface 42 of the cross member 24. The toolslot 142 may be spaced apart from a flexible arm 144 having a barb 146and a release tab 148. The release tab 148 may be located at an end ofthe flexible arm 144 and generally aligned with the tool slot 142. Therelease tabs 148 may extend toward each other and may be longer than thebarbs 146. As such, the release tabs may 148 may be disposed closer toeach other than the barbs 146. The barbs 146 may be configured to engagean associated notch 104 in the support post 28 when in a latchedposition to inhibit movement or removal of the support post 28 from thesupport post opening 60 as represented in solid lines in FIG. 12. Theflexible arm 144 may flex to an unlatched position in which the barbs146 are spaced apart from associated notches 104 to permit removal ofthe support post 28 from the support post opening 60 as shown in phantomin FIG. 12. A tool 128, such as a screwdriver, may be inserted throughthe tool slot 142 to engage the release tabs 148 and flex the flexiblearms 144 from the latched position to the unlatched position.

Referring to FIGS. 13 and 14, a fourth embodiment of a support postmounting portion 150 is shown. In this embodiment, two flexible arms 152that each have a barb 154 may be provided to engage notches 104 on atleast one support post 28. A connection member 156 may be provided thatextends between and connects the flexible arms 152. A gap 158 may beprovided below the connection member 156 to allow the connecting memberto flex away from a trim cover 160 or other flexible surface. Theconnection member 156 may also include a button portion 162 that may bedisposed proximate the trim cover 160. The flexible arms 152 may movebetween a latched position shown in FIG. 13 and an unlatched positionshown in FIG. 14. In the latched position, the barbs 154 may beconfigured to engage an associated notch 104 in the support post 28 toinhibit movement or removal of the support post 28 from the support postopening 60. The flexible arms 152 may flex to the unlatched position inwhich the barbs 154 are spaced apart from an associated notch 104 topermit removal of the support post 28 from the support post openings 60when sufficient force is exerted in the connection member 156.

Referring to FIGS. 15-17, a fifth embodiment of a support post mountingportion 170 is shown. In this embodiment, a cap 172 is provided that maybe disposed in the support post opening 60. The cap 172 may include ahole 174 through which the support post 28 may extend. The cap 172 mayalso include a flange 176 that may extend outward from the hole 174 andthat may be disposed at a first end of the cap 172. One or more wedgearms 178 may extend from a second end of the cap 172 disposed oppositethe first end and/or the flange 176. The wedge arms 178 may include anangled portion 180 that may be configured to engage and actuate aflexible arm 124. In addition, a hook 182 may be disposed on the cap172. In the embodiment shown, the hook 182 extends from the wedge arm178 and extends along a surface of the flexible arm 124 disposedopposite the barb 126.

The cap 172 may move between a latched position in which the flexiblearm 124 engages and inhibits removal of the support post 28 and anunlatched position in which the flexible arm 124 flexes to permitremoval of the support post 28. In FIG. 16, the flexible arm 124 isshown in an exemplary latched position. In this embodiment, the barb 126may engage the notch 104 and the hook 182 may be disposed proximate asurface of the flexible arm 124 disposed opposite the barb 126. The hook182 may be offset to a side of the wedge arm 178 to permit a portion ofthe wedge arm 178 to be aligned with the flexible arm 124 when the cap172 is rotated to a position where the hook 182 is spaced apart from theflexible arm 124. As such, the hook 182 may inhibit the flexible arm 124from flexing prior to rotation of the cap 172 even if the cap 172 isactuated downward toward the flexible arm 124.

In FIG. 17, the cap 172 is shown in an exemplary unlatched position. Inthis position, the cap 172 has been rotated about the axis 62 such thatthe hook 182 is not disposed proximate a surface of the flexible arm 124disposed opposite the barb 126. The flexible arm 124 may flex when thecap 172 is actuated toward the flexible arm 124. For clarity, the hook182 on the wedge arm 178 on the left side of FIG. 17 is not shown. Inaddition, the hook 182 may be omitted in one or more embodiments. If thehook 182 is omitted, then the cap 172 may be actuated toward theflexible arm 124 without rotation to flex the flexible arm 124 from thelatched position to the unlatched position.

While embodiments of the invention have been illustrated and described,it is not intended that these embodiments illustrate and describe allpossible forms of the invention. Rather, the words used in thespecification are words of description rather than limitation, andvarious changes may be made without departing from the spirit and scopeof the invention.

What is claimed is:
 1. A seat assembly comprising: a seat back having aframe assembly that includes a unitary plastic cross member that extendsbetween first and second side members, wherein the cross memberincludes: a first support post opening; and a first flexible arm that isdisposed in the cross member proximate an end of the first support postopening, wherein the first flexible arm has a first barb; and a supportpost for supporting a headrest, the support post having a first notch;wherein the first flexible arm is configured to flex between a latchedposition in which the first barb is disposed in the first notch toinhibit movement of the support post and an unlatched position in whichthe first barb is spaced apart from the notch to permit removal of thesupport post from the first support post opening.
 2. The seat assemblyof claim 1 wherein the cross member further comprises an arcuate contactsurface that extends from the first flexible arm and engages an end ofthe support post.
 3. The seat assembly of claim 1 wherein the crossmember has a top wall that includes a tool slot that is aligned with thefirst flexible arm and is configured to receive a tool that flexes thefirst flexible arm to the unlatched position when sufficient force isexerted by the tool upon the first flexible arm.
 4. The seat assembly ofclaim 3 wherein the tool engages the first barb to flex the firstflexible arm to the unlatched position.
 5. The seat assembly of claim 3wherein the tool slot extends outwardly from the first support postopening and away from the support post.
 6. The seat assembly of claim 1wherein the support post has a second notch that is spaced apart fromthe first notch and the cross member has a second flexible arm that isspaced apart from the first flexible arm and that has a second barb,wherein the second flexible arm is configured to flex between a latchedposition in which the second barb is disposed in the second notch toinhibit movement of the support post and an unlatched position in whichthe second barb is spaced apart from the second notch to permit removalof the support post from the first support post opening.
 7. The seatassembly of claim 6 wherein the first flexible arm moves away from thesecond flexible arm when the first flexible arm and the second flexiblearm move from their respective latched positions toward their respectiveunlatched positions.
 8. The seat assembly of claim 6 wherein the crossmember further comprises an arcuate contact surface that extends betweenthe first flexible arm and the second flexible arm and engages an end ofthe support post.
 9. The seat assembly of claim 6 wherein the crossmember has a top wall that includes a tool slot that is aligned with thefirst flexible arm and the second flexible arm and is configured toreceive a tool that flexes the first flexible arm and the secondflexible arm to their respective unlatched positions when sufficientforce is exerted by the tool upon the first flexible arm and the secondflexible arm.
 10. The seat assembly of claim 9 wherein the tool slot isspaced apart from the first support post opening.
 11. The seat assemblyof claim 6 wherein the first flexible arm has a first release tab andthe second flexible arm has a second release tab, wherein the firstrelease tab is longer than the first barb and the second release tab islonger than the second barb.
 12. The seat assembly of claim 11 whereinthe cross member includes a tool slot and wherein the first and secondflexible arms move away from each other when a tool is inserted throughthe tool slot and exerts sufficient force upon the first release tab andthe second release tab.
 13. The seat assembly of claim 11 wherein thefirst release tab is disposed at an end of the first flexible arm andthe second release tab is disposed at an end of the second flexible arm.14. The seat assembly of claim 13 wherein the first release tab isdisposed opposite and extends toward the second release tab such thatthe support post is not disposed between the first release tab and thesecond release tab.
 15. The seat assembly of claim 1 wherein the crossmember further comprising a second support post opening, a secondflexible arm disposed proximate the second support post opening, and aconnection member that extends from the first flexible arm to the secondflexible arm, wherein the first and second flexible arms disengage thesupport post when sufficient force is exerted on the connection member.16. The seat assembly of claim 15 wherein the connection member includesa button portion that is disposed proximate a trim cover.
 17. The seatassembly of claim 16 wherein a gap is provided below the connectionmember to allow the connection member to flex away from the trim cover.18. The seat assembly of claim 1 further comprising a cap disposed inthe first support post opening, wherein the cap includes a hole thatreceives the support post, a flange disposed around the hole, and awedge arm that is disposed at an end of the cap that is disposedopposite the flange for engaging the first flexible arm, wherein thefirst flexible arm disengages the first notch when the cap is rotatedand actuated toward the flexible arm.
 19. The seat assembly of claim 18wherein the cap further comprises a hook disposed on the wedge arm thatinhibits the first flexible arm from disengaging the first notch priorto rotation of the cap.